Fastening tab means for a disposable diaper

ABSTRACT

A disposable diaper having a moisture-impermeable backing sheet and an absorbent pad suspended on the backing sheet is provided with a fastening tab means attached at one end to the backing sheet near one edge of the diaper. A terminal free portion of the fastening tab means extends inwardly from the diaper edge and lies substantially flat against the inside surface of the diaper, and an intermediate portion of the fastening tab means is doubled over on itself to form a relatively small section having two tab thicknesses outside the perimetric limits of the diaper.

United States Patent 1191 Mesek et al.

1 FASTENING TAB MEANS FOR A DISPOSABLE DIAPER [75] Inventors: FrederickK. Mesek, Downers Grove; Ludwig Tritsch, Wilmette, both of I11.

[73] Assignee: Johnson & Johnson, New

Brunswick, NJ.

[22] Filed: Sept. 3, 1974 [2]] Appl. No.: 503,013

. [52] US. Cl 128/287; 128/284 [51] Int. Cl. A61F 13/16 [58] Field ofSearch 128/284, 287, 290 R, 286

[56] References Cited UNITED STATES PATENTS 2,714,889 8/1955 Chambers128/287 3,750,669 8/1973 DeLuca 128/287 3,776,234 12/1973 Hoey 128/287Nov. 18, 1975 3,794,038 2/1974 Buell 128/287 3,810,472 5/1974 Aldinger128/287 3,848,594 11/1914 B11811 128/284 3,848,596 11/1974 Pennau128/284 Primary Examiner-Aldrich F. Medbery [57] ABS 10 Claims, 5Drawing Figures U.S. Patent Nov. 18, 1975 3,920,016

FIG. 4

FIG. 5

FASTENING TAB MEANS FOR A DISPOSABLE DIAPER BACKGROUND OF THE INVENTIONThis invention relates to diapers. More particularly, this inventionrelates to diapers which are adapted to be used once and then discarded.

Disposable diapers provide substantial advantages in convenience overconventional diapers and commonly have a generally quadrilateralconfiguration with straight or curvilinear longitudinal edges. Recently,disposable diapers have been secured about an infant by means ofadhesive tape tabs which are affixed to the diaper along a longitudinaledge thereof, thus eliminating the need for extraneous fasteners, suchas pins. However, such tabs usually project above and/or beyond theconfines of the diaper to a considerable extent and interfere with theefficient manufacture, folding and packing of the diaper. I

U.S. Pat. No. 3,776,234 to Hoey proposes to fold the tab over on itselfat the diapers edge and to adhesively attach a portion of thefolded-over tab segment to theinside surface-of the diaper in order tokeep the tab from interfering with manufacturing machinery and with thefolding and packaging operation. This requires .that the backing sheetof the diaper be folded over to be present at the front face or insideof the diaper, and a relatively involved tab design is provided whichcomplicates manufacturing manipulation. Also, undesirable tearing of thediaper facing fabric may result if such a tab is adhesively attached tothe facing fabric of the diaper. U.S. Pat. No. 3,646,937 to Gellertshows a fastening tab provided with a release surface which ispermanently bonded to the inside surface of the diaper; however, such anarrangement is disadvantageous because the release surface may be placedin contact with the infants skin when the diaper is used.

SUMMARY OF THE INVENTION The present invention contemplates a disposablediaper of substantially quadrilateral configuration, i.e., rectangularor contoured configuration, having an inside surface for directiontoward an infant and an outside surface for direction away from theinfant. The disposable diaper comprises a thin, flexible backing sheetof substantially moisture impermeable material, a moisture-retaininglayer including a pad of highly absorbent material superposed on saidbacking sheet and attached thereto, and a fastening tab means atopposite sides of the diaper having a first tab portion attached to thebacking sheet near a longitudinal edge of the diaper. A porous facinglayer substantially coextensive with the backing sheet can also beprovided as part of the moisture-retaining layer. Each tab meansincludes a second tab portion adjoining the first tab segment anddoubled over on itself so as to form a relatively small folded sectionoutside the perimetric limits of the diaper. Each tab means furtherincludes third tab portion having a pressure sensitive adhesive surfacefor attachment to the outside surface of the diaper when the diaper isapplied to the infant which third tab portion adjoins the second tabsegment and lies substantially flat against the inside surface of thediaper. Prior to use the adhesive surface on the third tab portion bearsa release sheet which is readily removable upon use.

BRIEF DESCRIPTION OF THE DRAWING In the drawing,

FIG. 1 is a perspective view showing a diaper of this invention in theform normally assumed during use;

FIG. 2 is a plan view of the diaper shown in FIG. 1;

FIG. 3 is a fragmentary sectional view taken along plane 3-3 in FIG. 2and enlarged to show interior detail;

FIG. 4 is a similar fragmentary sectional view showing a furtherembodiment of the present invention; and

FIG. 5 is a fragmentary sectional view showing another embodiment ofthis invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, disposablediaper 10 is shown in a form usually assumed when applied to an infant.Inside surface 11 is directed toward the infant and outside surface 12is directed away from the infant. Fastener tab means 13 and 14 arelocated near longitudinal edges 15 and 16, respectively, and adjacent torespective top corners 17 and 18 (FIG. 2). As diaper 10 is applied tothe torso of an infant, it assumes the configuration shown in FIG. 1,and top corners l7 and 18 overlap bottom corners 19 and 20. As shown inFIGS. 2 and 3, diaper 10 is made up of thin, flexible backing sheet 21which is substantially moisture-impermeable. A suitable backing sheetcan be made of an opaque polyethylene web about 0.001 inch thick.Another suitable flexible sheet material is a polyethylene terephthalateweb about 0.0005 inch thick. Centrally disposed, highly absorbent pad 47is part of moistureretaining layer 22 which is superposed on backingsheet 21 and attached thereto in any convenient manner, e.g., byadhesive attachment or the like. If desired, an additional layer of anon-woven fabric of the type shown in U.S. Pat. No. 3,730,184 to Mesekcan be applied over absorbent pad 47 as part of moisture-retaining layer22. Another diaper construction eminently suitable for practicing thepresent invention is shown in U.S. Pat. No. 3,683,916 to Mesek et al.Still other suitable disposable diaper structures are shown in U.S. Pat.No. 3,612,055 to Mesek et al. which teaches the use of a porous facinglayer over a moisture-retaining layer or layers, and in U.S. Pat. No.Re. 26,151 to Duncan et al.

The fastening tab means in accordance with the present invention can bemade from polyethylene tape stock, polypropylene tape stock, or thelike, as illustrated in FIGS. 3, 4 and 5. As shown in FIG. 3, fasteningtab 13 comprises a first tab portion 23 which is attached by means ofadhesive layer 24 to backing sheet 21 near a longitudinal edge of thediaper. Second tab portion 25 adjoins first tab segment 23 and isdoubled over on itself so as to form a relatively small section of twotab thicknesses which are adhesively attached to each other by means ofadhesive layer 24. Second tab portion 25 is considerably smaller thanfirst tab portion 23 and extends beyond the perimetric limits of diaperl0 usually about 0.125 inch. Third tab portion 26 adjoins second tabportion 25 and extends inwardly over the inside surface of the diaper.The dimensions of second tab portion 25 are selected so as to maintainthird tab portion 26 in a substantially flat overlying position relativeto the inside surface of the diaper. In order to prevent adhesion ofthird tab portion 26 to the inside surface of the diaper, release sheet27 is provided covering that portion of adhesive layer 24 which iscoextensive with tab portion 26. Advantageously release sheet 27 can beprovided with free end 28 which is folded back against release sheet 27and provides a convenient grip means for pulling release sheet 27 awayfrom the adhesive surface when the diaper is prepared for use. Therelease sheet can be made of a wide variety of non-tacky materials,e.g., silicone-coated paper strip, smooth non-adherent plastic strip,such as polyethylene or polypropylene sheet, treated with siliconerubber or the like, which is readily removable from pressure sensitiveadhesive surface 24 when the diaper is to be secured about an infant.

The adhesive-to-adhesive contact of the doubledover parts of portion 25provides a substantially permanent fold or pleat. In the event it isdesired to provide a lesser degree of adhesion between the doubled-overparts so that the formed fold or pleat can be removed from tab 13 whenthe diaper is prepared for use, adhesive layer 24 can be made less tackyin the region of segment 25 by applying a powder such as talc over thesurface of adhesive layer 24, in an amount which renders the surfacereleasably tacky.

In the embodiment illustrated in FIG. 4, flexible backing sheet 29 andmoisture-retaining layer 30 superposed thereon comprises a diaperprovided with fastening tab 31. First tab portion 32 is secured tobacking sheet 29 by adhesive layer 33. Second tab portion 34 is doubledover on itself to form a fold and third tab portion 35 adjoins segment34. Adhesive layer 33 is coextensive with tab 31. Release sheet 36covers the adhesive surface of third tab portion 35 and has one end .37extending into the fold formed by the doubled-over parts of portion 34so that the juxtaposed adhesive surfaces on portion 34 are adhesivelyattached to end 37 of release sheet 36. End 37, of course, is providedwith suitable release surfaces on both sides so that it is readilyreleased from adhesive layer 33 when tab 31 is used. Release sheet 36also extends beyond tab segment 35 so as to provide free end 38 whichserves as a grip means for removing the release sheet so as to uncoverthe adhesive surfaces on tab portions 34 and 35. In a further variant ofthis embodiment, end 37 can be provided with a release coating on onlyone side thereof and severed from or severably attached to the mainportion of release sheet 36 so that end 37 is retained on adhesive layer33 as a separate release material segment when the rest of release sheet36 is removed preparatory to placing the diaper in use. If greaterholding strength is desired for keeping the tab portion 34 in thedoubled-over configuration, end 37 of release sheet 36 can be perforatedto provide limited adhesive-to-adhesive contact for doubled-over portion34.

Where both the flexible backing sheet and the fastening tab are made ofa thermoplastic material which can be readily fused, the fastening tabcan be bonded directly to the backing sheet of the diaper. Also, thedoubled-over tab portion which extends beyond the perimetric limits ofthe diaper can be lightly heat-bonded or tack-bonded together toreleasably maintain the doubled-over configuration until such time whenthe diaper is used. Alternatively, the doubled-over tab portion can bepermanently fused together without the need for an auxiliary adhesive.This is illustrated in FIG. wherein thermoplastic backing sheet 39 isprovided with fastening tab 40 having first tab portion 41 fused tobacking sheet 39. Second tab portion 42 is folded over on itself and theresulting juxtaposed thicknesses are fused together by suitableapplication of heat. Third tab portion 43 which adjoins tab portion 42is provided with adhesive layer 44 which is covered with release sheet45. Free end 48 of release sheet 45 is folded back in a manner similarto that shown in FIG. 3. Free end 48 abuts the edge ofmoisture-retaining layers 46 superposed on backing sheet 39 withoutinterfering with the generally flat position of tab portion 43 whichoverlies the inside surface of moisture-retaining layer 46 free ofattachment to the diaper.

Suitable pressure-sensitive adhesives for the present purposes are knownin the art and possess good tack, good cohesive strength, good moistureresistance and good resistance to aging. Illustrative of such adhesivecompositions are mixtures of natural or synthetic rubber with zinc oxideand various resins, natural or synthetic rubber or resin latices, tackyacrylic polymers or copolymers, and the like.

In use, a disposable diaper equipped with the fastening tab means ofthis invention is applied to the infant by laying out the diaper on asuitable flat surface and placing the infant thereon so that thewaist-underlying end of the diaper is that having the fastener tab. Theother end of the diaper then extends downwardly between the infantslegs. Next, the downwardly extending end of the diaper is brought upbetween the infants legs to a position contiguous to the front of theinfants waist. The diaper is thereafter secured to the infant by placingthe corners of the waist portion of the abdomen-covering end as fararound the infants waist as they will go and by bringing the corners ofthe underlying end of the diaper into an overlapping relationship withthe aforementioned corners so that the diaper snugly encircles theinfants waist. The release sheets are then lifted from the adhesivesurfaces provided on the third tab segment of each fastening tab and thecorners of the underlying end of the diaper are fixed in the aforesaidoverlapping position by simply urging the pressure sensitive adhesivesurfaces on each fastening tab in contact with the outside surface ofthe underlying diaper backing sheet thus custom fitting the diaper aboutthe infant.

The foregoing description and the drawing are illustrative but are notto be taken as limiting. Still other variations and modifications arepossible without departing from the spirit and scope of this invention.

We claim:

1. A disposable diaper of substantially quadrilateral configurationdefined by longitudinal and transverse peripheral edges and having aninside surface for direction toward an infant when the diaper is worn bythat infant and an outside surface for direction away from said infant,which disposable diaper comprises a thin flexible backing sheet ofsubstantially moistureimpermeable material; a moisture-retaining layerincluding a pad of absorbent material superposed on said backing sheetand attached thereto; and a fastening tab means having a first tabportion attached to a portion of said backing sheet superposed by saidmoisture-retaining layer and near a longitudinal edge of said diaper, adoubled over second tab portion adjoining the first tab portion andattached to itself and forming a relatively small folded section outsidethe perimetric limits of the diaper, and a third tab portion adjoiningthe second tab segment, extending over to lie substantially flat againstsaid diaper inside surface but free from attachment thereto, and havinga pressure sensitive adhesive surface for attachment to the outsidesurface of the diaper when the diaper is applied to the infant.

2. The disposable diaper in accordance with claim 1 wherein thedoubled-over portions of said second tab segment are adhesively attachedto each other.

3. The disposable diaper in accordance with claim 2 wherein said secondtab segment is provided with a pressure sensitive adhesive having areleasably tacky surface and wherein the doubled-over portions areadhesively but releasably attached to each other.

4. The disposable diaper in accordance with claim 1 wherein said secondtab segment is provided with a pressure sensitive adhesive layer onjuxtaposed surfaces of the second tab segment and said juxtaposedsurfaces are adhesively attached to opposite sides of a terminal portionof a strip of release sheet interposed therebetween, and wherein saidterminal portion is perforated and is severable from the remainder ofsaid strip of release sheet.

5. The disposable diaper in accordance with claim 3 wherein said stripof release sheet additionally covers the adhesive surface on said thirdtab segment and is provided with a free end extending beyond said thirdtab segment.

6. The disposable diaper in accordance with claim 1 wherein said backingsheet and said fastening tab means both are made of a thermoplasticmaterial, wherein said first tab segment is fused to said backing 6sheet, and wherein the doubled-over portions of said second tab segmentare releasably bonded to each other.

7. The disposable diaper in accordance with claim 1 wherein the adhesivesurface on said third tab segment is covered by a release sheet.

8. The disposable diaper in accordance with claim 7 wherein said releasesheet is provided with a free end near the juncture of said second tabsegment and said third tab segment and wherein said free end is foldedback against said release sheet.

9. The disposable diaper in accordance with claim 1 wherein said secondtab segment is provided with a pressure sensitive adhesive layer onjuxtaposed surfaces thereof, wherein a release material segment isinterposed between said juxtaposed surfaces, and wherein a strip ofrelease sheet covers the adhesive surface on said third tab segment.

10. The disposable diaper in accordance with claim 1 wherein saidbacking sheet and said fastening tab means both are made of athermoplastic material, wherein said first tab segment is fused to saidbacking sheet, and wherein the doubled-over portions of said second tabsegment are releasably bonded to each other.

UNITED STATES PATENT AND TRADEMARK OFFICE QETIFICATE OF CORRECTIONPATENT NO. 3,920,016 DATED November 18,1975 INVENTCWS) Frederick K.Mesek and Ludwig Tritsch 'ed first en's-r HDDSZHS in fhe ubove-edenhfiedpateni and that said Letters Patent .1 T slmw imgw' In the Abstract,line 2, "suspended" should read superposed In Column 1, line 21,"packing" should read packaging should read In Column 1, line 58,"segment" portion In Column 1, line 65, "segment" should read portion InColumn 2, should read line 5h, "segment" portion should read In Column3, line 29,

"segment" portion Signed and Scaled this thirtieth D f March 1976 [SEAL]A ttes t:

C. MARSHALL DANN Commissioner ofPaIenIs and Trademarks RUTH C. MASONAlresling Officer

1. A disposable diaper of substantially quadrilateral configurationdefined by longitudinal and transverse peripheral edges and having aninside surface for direction toward an infant when the diaper is worn bythat infant and an outside surface for direction away from said infant,which disposable diaper comprises a thin flexible backing sheet ofsubstantially moisture-impermeable material; a moisture-retaining layerincluding a pad of absorbent material superposed on said backing sheetand attached thereto; and a fastening tab means having a first tabportion attached to a portion of said backing sheet superposed by saidmoisture-retaining layer and near a longitudinal edge of said diaper, adoubled over second tab portion adjoining the first tab portion andattached to itself and forming a relatively small folded section outsidethe perimetric limits of the diaper, and a third tab portion adjoiningthe second tab segment, extending over to lie substantially flat againstsaid diaper inside surface but free from attachment thereto, and havinga pressure sensitive adhesive surface for attachment to the outsidesurface of the diaper when the diaper is applied to the infant.
 2. Thedisposable diaper in accordance with claim 1 wherein the doubled-overportions of said second tab segment are adhesively attached to eachother.
 3. The disposable diaper in accordance with claim 2 wherein saidsecond tab segment is provided with a pressure sensitive adhesive havinga releasably tacky surface and wherein the doubled-over portions areadhesively but releasably attached to each other.
 4. The disposablediaper in accordance with claim 1 wherein said second tab segment isprovided with a pressure sensitive adhesive layer on juxtaposed surfacesof the second tab segment and said juxtaposed surfaces are adhesivelyattached to opposite sides of a terminal portion of a strip of releasesheet interposed therebetween, and wherein said terminal portion isperforated and is severable from the remainder of said strip of releasesheet.
 5. The dIsposable diaper in accordance with claim 3 wherein saidstrip of release sheet additionally covers the adhesive surface on saidthird tab segment and is provided with a free end extending beyond saidthird tab segment.
 6. The disposable diaper in accordance with claim 1wherein said backing sheet and said fastening tab means both are made ofa thermoplastic material, wherein said first tab segment is fused tosaid backing sheet, and wherein the doubled-over portions of said secondtab segment are releasably bonded to each other.
 7. The disposablediaper in accordance with claim 1 wherein the adhesive surface on saidthird tab segment is covered by a release sheet.
 8. The disposablediaper in accordance with claim 7 wherein said release sheet is providedwith a free end near the juncture of said second tab segment and saidthird tab segment and wherein said free end is folded back against saidrelease sheet.
 9. The disposable diaper in accordance with claim 1wherein said second tab segment is provided with a pressure sensitiveadhesive layer on juxtaposed surfaces thereof, wherein a releasematerial segment is interposed between said juxtaposed surfaces, andwherein a strip of release sheet covers the adhesive surface on saidthird tab segment.
 10. The disposable diaper in accordance with claim 1wherein said backing sheet and said fastening tab means both are made ofa thermoplastic material, wherein said first tab segment is fused tosaid backing sheet, and wherein the doubled-over portions of said secondtab segment are releasably bonded to each other.